Removal

Synchro Ring and Gear Inspection









Removal

1. M/T Change Lever Assembly





1. Remove the change lever assembly (A).

2. Remove the 8 x 10 mm dowel pins (B).

2. Back Up Light Switch





1. Remove the back-up light switch (A) and the 18 mm sealing washer (B).

3. M/T Output Shaft Speed Sensor





1. Remove the output shaft (countershaft) speed sensor (A), the plain washer (B), and the O-ring (C).

4. M/T Transmission Housing Assembly





1. Remove the detent bolts (A), the 12 mm sealing washers (B), the detent ball springs (C), and the steel balls (D).





2. Remove the 8 mm flange bolts in a crisscross pattern in several steps.





3. Remove the 32 mm sealing cap (A).

4. While expanding the 69 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C).

5. Release the snap ring pliers, and remove the transmission housing.

6. Remove the 14 x 20 mm dowel pins (D).

5. M/T Reverse Shift Fork





1. Remove the reverse shift fork (A).

6. Reverse Idler Gear





1. Remove the reverse idler gear (A) and the reverse idler gear shaft (B).

7. M/T Mainshaft and Countershaft and Shift Fork Assembly





1. Apply a thin layer of tape to the mainshaft splines to protect the seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

2. Remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).

3. Remove the 26 mm washer (E).

4. Remove the 36 mm spring washer (F).

8. M/T Mainshaft 5th Gear





1. Support the tapered cone ring (A) on the bearing separator.

2. Press the mainshaft out of the angular ball bearing (B).





3. Support 5th gear (A) on the bearing separator.

4. Press the mainshaft out of the 5th synchro hub (B) and 5th gear.

9. M/T Mainshaft 3rd and 4th Gear





1. Support 3rd gear (A) on the bearing separator.

2. Press the mainshaft out of the 3rd/4th synchro hub (B) and 3rd gear.

10. M/T Countershaft





1. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

2. Remove the special bolt (B) (left-hand threads).





3. Support the ball bearing (A) on steel blocks (B).

4. Use a press (C) and an attachment (D) to press the countershaft out of the ball bearing.





5. Remove the 32 mm shim (A).

6. Remove the distance collar (B).





7. Support 4th gear (A) on the bearing separator.

8. Press the countershaft (B) out of 4th gear and 5th gear using an attachment (C) and the press (D).





9. Support 2nd gear (A) on the bearing separator.

10. Press the countershaft (B) out of 2nd gear and 3rd gear using an attachment (C) and the press (D).